Strong and Durable Chains for Industrial Use
Chains are a critical component in many industrial settings, used for lifting, pulling, conveying, and transmitting power. Selecting the right industrial-grade chain is essential to ensure safety, efficiency, and longevity in demanding environments.
Choosing the Right Chain Strength and Size
Consider the application to determine the required chain size and minimum breaking strength. Larger chain sizes are needed for heavier loads. Breaking strength indicates how much load a chain can handle before failure. For overhead lifting, safety standards recommend a breaking strength of at least 5 times the maximum load.
Common Chain Sizes
- 1/4 in. chain - 1,250 lb breaking strength
- 5/16 in. chain - 2,250 lb breaking strength
- 3/8 in. chain - 3,150 lb breaking strength
- 1/2 in. chain - 5,400 lb breaking strength
Chain Materials - Pros and Cons
Chains are commonly made from metals like steel, iron, and alloy steel. Consider the operating environment to choose the best metal.
| Material | Benefits | Drawbacks |
|---|---|---|
| Carbon Steel | Inexpensive, high strength | Susceptible to rust |
| Stainless Steel | Corrosion resistance, high strength | More expensive |
| Alloy Steel | Very strong, some corrosion resistance | Higher cost |
| Iron | Low cost | Lower strength, rusts easily |
Protecting Chains from Rust and Corrosion
For steel chains used outdoors or in wet environments, protect them from corrosion:
- Apply lubricants that contain rust inhibitors
- Hot-dip galvanization coats the chain in a protective zinc layer
- Electroplated zinc coatings provide corrosion resistance
- Powder coatings seal and insulate the chain
Lubrication and Maintenance Tips
Proper lubrication reduces internal wear and elongation. Follow the chain manufacturer's lubricant guidelines. General tips include:
- Oil-based lubricants attract less dirt and debris
- Greases adhere better for vertical or dusty conditions
- Inspect chains periodically for signs of wear
- Clean dirty chains before lubricating
- Avoid over-lubricating which leads to waste and leaks
Following these chain selection and maintenance practices will lead to optimal performance and service life even under demanding industrial loads and environments.
Choosing the Right Chain Strength and Size
Selecting the proper strength and size of chain is crucial for industrial lifting, pulling, and conveying applications. The chain must be strong enough to support the loads safely while not being oversized and wasting cost and space.
Determine the Maximum Working Load
Consider the weight of objects being lifted or conveyed. Factor in acceleration forces from starting and stopping. For lifting, include the total weight of the load plus any lifting attachments. Select a chain rated for the maximum expected working load.
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Minimum Breaking Strength
This refers to the force needed to break the chain. ASME B30 safety standards for lifting set the minimum breaking strength at:
- At least 5 times the maximum load for overhead lifting
- At least 4 times the maximum load for below-the-hook lifting
Higher safety factors may be warranted for critical or dangerous lifts.
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Chain Size
Larger chain sizes are stronger but also heavier. Consider the tradeoffs:
| Chain Size | Typical Minimum Breaking Strength | Weight per Foot |
|---|---|---|
| 1/4" | 1,250 lbs | 0.2 lbs |
| 5/16" | 2,250 lbs | 0.3 lbs |
| 3/8" | 3,150 lbs | 0.5 lbs |
| 1/2" | 5,400 lbs | 0.9 lbs |
Allow for Elongation
Chains elongate over time from repeated loading. Only apply around 80% of the chain's breaking strength when sizing for an application. This accounts for elongation over the life of the chain.
Consult the Manufacturer
Reputable chain manufacturers provide load capacity tables to make sizing easier. When in doubt, consult them for recommendations based on your specific application.
Choosing the optimal chain strength and size improves safety and performance. Consider all factors including expected loads, safety margins, chain weight, and elongation over time.
Chain Materials - Pros and Cons
Chains are manufactured from various metals, each with their own advantages and disadvantages. Selecting the right chain material depends on the operating conditions and application requirements.
Carbon Steel
The most common chain type. It offers:
- High strength - Used for heavy lifting and pulling
- Low cost
- Easy to fabricate and weld
Drawbacks:
- Prone to rusting unless properly lubricated and maintained
- Not suitable for saltwater or acidic conditions
Stainless Steel
Provides excellent corrosion resistance while maintaining strength. Types include:
- 304 - Resists rust in mild environments
- 316 - Superior corrosion resistance for saltwater, chemicals
Benefits:
- Low maintenance, no need for heavy lubrication
- Longer chain life
Drawbacks:
- Up to 5 times costlier than carbon steel
- Lower maximum strength than alloy steel
Alloy Steel
Alloyed with metals like nickel, chromium, and manganese. Provides:
- Extremely high strength for heavy loads
- Moderate corrosion resistance
Best for demanding applications like mining, oil drilling, marine. Downsides:
- Expensive
- Difficult to weld and fabricate
Iron
Low strength but very low cost. Used for light duty applications like:
- Securing gates, doors
- Tow chains
- Decorative conveyor systems
Susceptible to rust so avoid wet environments. Frequently zinc coated for corrosion resistance.
Consider chain material along with strength, corrosion resistance, and budget when selecting chains. The right choice depends on the operating conditions and loads.
Protecting Chains from Rust and Corrosion
For chains used in wet, outdoor, or chemically harsh environments, corrosion can lead to premature failure. Proper protective measures are essential to extend service life.
Lubricants with Rust Inhibitors
Regular lubrication forms a protective barrier and reduces internal wear and friction. Look for lubricants containing rust inhibitors like:
- Zinc phosphate
- Calcium sulfonate
- Sodium nitrite
The lubricant should be compatible with chain material and application environment. Reapply frequently according to manufacturer specifications.
Galvanization
Chains are dipped in a bath of molten zinc which coats the surface. Benefits:
- Low cost protection
- Zinc layer sacrifices itself to prevent base metal corrosion
- Can extend chain life up to 20 years in mild environments
Galvanized coatings withstand about 100 hours of salt spray exposure.
Electroplating
A layer of zinc is deposited onto the chain through electroplating. Advantages:
- Thinner coating than hot-dip galvanizing
- Protects internal chain surfaces
- More corrosion resistance - up to 500 hours of salt spray
Electroplating is suited for small to medium chains in corrosive environments.
Powder Coating
A polymer coating is baked onto the chain. It provides:
- Excellent barrier against moisture
- High chemical and abrasion resistance
- Wide range of color options
Powder coats are more expensive but offer superior life over other methods. Ideal for food-grade and chemically-exposed applications.
Consider the level of corrosion protection needed and operating environment when selecting the optimal chain protection method.
How Chains Can Be Used In Industrial Hardware?
Chains are a versatile piece of hardware that can be used in various industrial applications. Here are some ways chains can be used in industrial hardware:
- Power transmission: Chains are used for the transmission of power where shafts are separated at distances greater than that for which gears are practical. They are commonly used in bikes, agricultural machinery, compressors, engine camshafts, and other applications.
- Conveyor systems: Conveyor chain drives are crafted especially for material transportation and come in hundreds of different designs. They are used in industries such as packaging, automotive, food and beverage production, pharmaceuticals, and textiles.
- Overhead lifting: Chains are often used for securing vehicles to flatbed trailers, but they can also be used to help lift heavy cargo onto a cargo ship.
- Hoisting and hauling: Chain hoists are probably the most common piece of machinery used to lift and lower equipment. They can lift massive weights with very little effort using pulleys.
- Amplifying work: Chains have been used to amplify work for hundreds of years. With roller chains, one end of the chain is connected to a sprocket driven by the engine where energy is being converted. The other end connects with the load to be shifted.
- Block chains: The chains used in conveyor belts are commonly block chains, which consist of solid or laminated blocks connected by side plates and pins. The blocks engage with teeth on sprocket wheels.
What Are The Most Common Materials Used To Make Industrial Chains?
The most common materials used to make industrial chains are:
- Steel: Steel is the most common material used to make industrial chains. It is strong, durable, and can be easily welded. Steel chains can be further classified into alloyed, high-alloyed, and carbonaceous depending on the function of the chain.
- Stainless steel: Stainless steel is also used to produce chains with greater corrosion resistance. In particular, manufacturers often use 304 and 316 stainless steel grades, which exhibit a higher carbon content than other stainless steel alloys and, therefore, higher tensile strength. The working load limits (WLLs) for stainless steel chains are more dependent on the chain size, with load capacities ranging between 375 pounds to 23,000 pounds.
- Galvanized steel: Galvanized steel is steel that has been coated with a layer of zinc to protect it from corrosion. Galvanized chains are commonly used in outdoor applications where they are exposed to the elements.
- Brass: Brass is a copper and zinc alloy that is often used in decorative chains. It is corrosion-resistant and has a gold-like appearance.
- Aluminum: Aluminum chains are lightweight and corrosion-resistant, making them ideal for use in applications where weight is a concern, such as in the aerospace industry.
- Iron: Iron is a strong and durable material that is often used in heavy-duty industrial chains. It is commonly used in applications where the chain will be exposed to high levels of stress and wear.
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